Method and articles employing ion exchange material

ABSTRACT

An electrode, preferably of a conductive polymer, has on its surface, preferably over all of its surface, an ion exchange material, preferably of significant thickness. Such a coated electrode may be used for sensing the presence or measuring the concentration of an ionic species, or for removal from or release of an ionic species into an electrode.

This application is a continuation of application Ser. No. 07/017,375,filed Feb. 20, 1987, now U.S. Pat. No. 4,888,098, which is acontinuation-in-part of appliation Ser. NO. 06/932,763, filed Nov. 19,1986, now abandoned, which is a continuation-in-part of application Ser.No. 06/831,758, filed Feb. 20, 1986, now abandoned the entire disclosureof each of which is incorporated herein by reference.

The present invention relates to methods and articles employing ionexchange materials, particularly in a cell, especially in anelectrolytic as opposed to galvanic cell. Such methods and articles findmany uses for example sensing a chosen chemical species (by which weinclude distinguishing between presence and absence and measurement ofconcentration), and extraction, concentration of dilution of a chosenspecies. Thus, the invention has at least two distinct, though related,aspects.

Ion exchange materials are generally solids or gels which contain, orwhich will react with an ionic material so as to contain, a replaceableionic species. Cation exchange materials are typically polymerscomprising branches containnig acidic groups, eg. --COOH, --SO₃ H, --PO₃H₂ and --C₆ H₄ OH, and metal eg. sodium and copper) salts thereof. Suchmaterials may exchange cations if provided with a suitable electrolyte,generally with no permanent change to the structure of the material.Ionic cation exchange material as are commonly subdivided into "strongacid" and "weak acid" types, which terms refer to the group's acidstrength or pK_(a). Cation exchange materials also include thosecomprising neutral groups or ligands that bind ions through coordinaterather than ionic bonds. For example, a pyridine group attached to amatrix will form a coordinate bond to Cu²⁺ inCuCl₂. Other catin exchangematerials includes polymers comprisng branches comprising complexing orchelating groups, eg. those derived from aminophosphic acid,aminocarboxylic acid, and hydroxamic acid.

A second type of ion exchange material is an anion exchange material.Such a material may exchange anions if provided with asutiableelectrolyte, again generally with no permanent change to the structureof the material. These materials generally comprise covalently bound,positively charged groups or neutral basic groups which upon protonationbecome charged. Examples include --NR₃ A, --NR₂ HA, --PR₃ A and --SR₂ A,where R is an alkyl, aryl or other organic gorup and A is an anion eg.halide. A specific exapleis a bound pyridine group which upon reactionwith acid, H⁺, forms a charged pyridinium group which is then capable ofexchanging aminos. An ion exchangers consisting of permanentlypositively charged groups are commonly referred to as "strong base"exchangers, and the sometimes neutral group materials are commonlyreferred to as "weak base" exchangers.

Ion exchange materials are widely used for extracting ions from liquids,eg. in water softening and deionization. The extracted ions can beremoved and theion exchange material regenerated, either chemically,using a suitable acid, base, or other regenerant, or electrochemicallyby aprocess in which the ion exchange material is seperated from theelectrodes by cation and anion permselective membranes. See for exampleU.S. Pat. No. 3,645,884 (Gilliland) and U.S. Pat. No. 4,032,452 (Davis)and an article entitled "Electroregenerated Ion-Exchange Deionization ofDrinking Water" by Davis in NTIS PB 270,910 (1977), the disclosure ofeach of which is incorporated herein by reference.

Other possible uses for ion exchange materials are disclosed in U.S.Pat. No. 4,210,501 (Dempsey et al.) U.s. Pat. No. 4,100,331 (Ingham etal.) and U.S. Pat. No. 3,297,484 (Niedrach) and an article entitled"Chemical Microstructures on Electrodes " by Faulkner in Chemical andEngineering News, Feb. 27, 1984, the disclosure of each of which isincorporated herein by reference.

We have now discovered that valuable results can be achieved by usingion exchange materials inconjunction with certain types of electrodes,by using them as sensors particularly for locating theh presence of anelectrolyte, by using them at significant thicknesses on electrodes, byproducing them insitu on electrodes, by using them to cover completelycertain electrodes, and by employing them in certain sizes and shapesparticularly in long lengths.

In a first set of embodiments, the invention is concerned with theextraction from a liquid, or concentration or dilution of a species in aliquid, which liquid in use functions as an electrolyte. Thus, anyliquid may be referred to herein as an electrolyte if it has a suitableionic resistance for the chosen application.

Thus, in one embodiment, the invention provides a method of replacing anionic species in an ion exchange material containing the ionic species,which method comprises passing a current through a first electrochemicalcell which comprises:

(1) a first electrode;

(2) an ion exchange material which

(a) contains an ionic species I_(1A), and

(b) is secured to and in electrical contact with the first electrode atan interface;

(3) a second electrode; and

(4) an electrolyte which electrically connects the first and secondelectrodes;

and in which cell an electrochemical reaction takes place at theinterface between the first electrode and the ion exchange material Aand generates an ionic species I_(2A) which causes the ionic speciesI_(1A) tobe replaced by a third ionic species.

That other species may be a species I_(3A) present in the electrolyte,which has the same polarity as species I_(1A) and which maintains itspolarity at the interface. Species I_(2A) may them have a polarityopposite to that of species I_(1A). A subsequent step may occur in aliquid containing an inic species I_(4A), namely the replacement ofspecies I_(3A) by I_(4A).

In the case of said subsequent step, the method may additionallycomprise the steps of passing current through a second electrochemicalcell which comprises:

(1) the first electrode, the polarity of the first electrode in thesecond electrochemical cell being opposite from the polarity of thefirst electrode in the first electrochemical cell;

(2) the ion exchnage material A which contains the species I_(4A) andwhich is secured to and in electrical contact with the first electrodeat the interface;

(3) a further electrode; and

(4) an electrolyte which electrically connects the first and furtherelectrodes, and which, at the interface between the first electrode andthe ion exchange material, undergoes an electrochemical reaction whichgenerates an ionic species I_(5A) which causes species I_(4A) to bereplaced by another species.

Where the other species is I_(3A) (and said subsequent step is notcarried out), the method may comprise the further step of passing thecurrent through a third electrochemical cell which comprises:

(1) the first electrode, the polarity of the first electrode in thethird electrochemical cell being opposite from the polarity of the firstelectrode in the first electrochemical cell;

(2) the ion exchange material which contains the species I_(3A) which issecured to and in electrical contact with the first electrode at theinterface;

(3) a further electrode; and

(4) an electrolyte which electrically connects the first and furtherelectrodes, and which, at the interface between the first electrode andthe ion exchange material A, undergoes an electrochemical reaction whichgenerates an ionic species I_(6A) which replaces the ionic speciesI_(3A).

Such methods can be used to extract species fromor release species intoa liquid or other electrolyte by means of various electrochemicalprocesses, for example water electrolysis, where a resulting ionicspecies directly or indirectly effects a modification of the ionexchange material. One purpose of such methods is the purification ofthe liquid, and another is the recovery of thespecies. For exampleindustrial wastes, sewage, or mining liquors etc. may be cleaned or saltwater may be desalinated. Examples of species that may desirably berecovered include heavy metals, cyanide, phosphates and sodium.Selective ion removal for recovery may be desirable in hydrometallurgical mining operations, metal plating operations and mining ofnatural waters such as the ocean.

For these methods, the capacity of the ion exchange material may beimportant, and we prefer that the material have an ion exchange capacityof at least 0.1, particularly at least 0.4 milliequivalents per gram.Preferably the material is i the form of a layer which has a thicknessof at least 0.04 mils (1×10⁻⁶ m), more preferably at least 0.4 mils(1×10⁻⁵ m), especially at least 4 mils (1×10⁻⁴ m). However, ion exchangematerials may increase substantially in volume between a dry state (inwhich they are generally manufactured) and a solvated state in which weprefere to use them. It is impossible using prior art techniques toprepare a device comprising an electrode and a layer of an ion exchangematerial which (a) is less (especially if substantially less) than 100%solvated, (b) is at least 0.04 mils (1×10⁻⁶ m) thick in the fullysolvated stae, and (c) is secured to an electrode sufficiently well tomake it possible to useit in the methods defined aboe. As will beexplained below, we have solved these problems by using an electrodethat can change its dimensions sufficiently to accommodate changes inthe dimensions of the ion exchange material, for exaple as the solvationof the ion exchange material incrases. Preferably the electrodecomprises a material which electrically and physically contacts the ionexchange material and which has an elastic modulus less than 10¹³dynes/cm², particularly les than 10¹¹ dynes/cm², especialy less than 10⁹dynes/cm². Particularly useful such materials are conductive polymers,ie. mixtures of a conductive filler and an organic polymer (this termbeing used to include polysiloxanes), the filler being dispersed in, orotherwise held together by, the organic polymer.

In a second set of embodiments, the invention is concerned with sensinga chosen chemical species. As mentioned above, this includesdistinguishing between presence and absence, measurement ofconcnetration, and detecting a change in concentration from some lowvalue to above some threshold value, which change may be several or manydecades of increase. In particular the invention provides monitoring bywhich we include methods which may be left running continuously(including automatic intermittant operation) and method where testing iscarried out from the time to time by an operator.

Thus, in a second embodiment the invention provides an apparatus (andcorresponding method) for monitoring an electrolyte to determine achange in the concentration of a chemical species in that electrolyte,or for monitoring for the presence of an electrolyte comprising achemical species, which apparatus comprises:

(1) a first electrode which is connectable to a source of electricpower;

(2) a second electrode which is connectable to the source of electricpower, and which is spaced apart from the first electrode, the first andsecond electrodes being so positioned and arranged that when aelectrolyte is between the electrodes and the source is connected to theelectrodes, current passes between the electrodes through theelectrolyte; and

(3) an ion exchange material which

(a) lies between the first and second electrodes so that when anelectrolyte is between the electrodes and current passes between theelectrodes, substantially all that current passes through the ionexchange material, and

(b) has an ionic resistance to the passage of that current which dependsupon the concentration of the chemical species in the electrolyte.

The term "depends on" is used herein to include any identifiablevariation in resistance with a variation in the concentration of thespecies.

The resistance between the electrodes depends on the resistance of theion exchange material, and that appears as a function of theconcentration of the chemical species. The resistance between theelectrodes as measured by any suitable device will include componentsdue to the resistance of any electrical connectinos, the resistance ofthe electrodes, the resistance of the electrolyte outside of the ionexchange material, and the resistance of the ion exchange materialitself. We prefer that the resistance of the ion exchange material belarge compared to the sum of the other resistances, since then thedesired change will result in a greater proportional change in the totalresistance. We prefer that the resistance of the ion exchange materialis at least 10%, more preferably atleast 50%, especially at least 90% ofthe total. A change in resistance may be measured by applying a constantcurrent and measuring a change in voltage, or by applying a constantvoltage and measuring a change in current. In either case, what is beingmeasured is a resistance that obtains at a significant current level.

The technique of the invention has significant advantages over theprincipal prior art technique for measuring ionic concentrations, thatof the pH meter. A pH meter typically comprises a pH responsive glassmembrane which in use develops a surface potential which is directlyrelated to the hydrogen ion concentration of its environment.

While a pH meter can accurately measure the concentration of hydrogenions, it does have some limittions. For example, it can only be used tomeasue concentrations at discrete points. Also, to remain immeditelyresponsive it must be stoed in water when not in use, which means thatit cannot e permanently installed if there is not water continuouslypresent. This is a particular problem if it is desired to measure thehydrogen ion concentation at a location that is difficult to access. ThepH meter is also easily contaminated, resulting in inaccurate ordrifting measurements.

The second embodiment of the invention allows the position of anelectrolyte to be determined. In this case, an electrode having acoating of an ion exchange material may be provided in elongate form(like a wire) having a length, say, at least 10, preferably at least 50,more preferably at least 100, times any transverse dimension. Theresistance of the eletrode in the longitudinal diretion is preferably atleast 10³, more preferably at least 10⁴, especially 10⁵ times itsresistance in any transverse direction. Thus the resulting elongatearticle may be laid for example along the underside of a pipe or otherplace where electrolyte may leak or otherwise be found. That article mayform part of an electrical circuit which is able to respond to a changein resistance of the ion exchange material, and optionaly provideinformation as to where along the elongate article the electrolytecaused the change in resistance.

Thus, the invention also provides an elongate flexible articlecomprising an elongate conductive core and a coating surrounding and inelectrical contact with the core comprising an ion exchange material,and a permeable jacket surrounding the ion exchange material, thearticle having a length at least 50 times any transverse dimension.

Preferably, the article additionally comprises a second elongateconductive core within the jacket. Such an article, amongst others, maybe used to lcoate an electrolyte by the following inventive method.

Thus, the invention further provides a method for monitoring for thepresence of an electrolyte and for locating electrolyte upon itspresence, which method comprises providing a system in which, upon thepresence of the electrolyte,

(1) electrical connection is made between an electrically conductivelocating member and an electrically conductive source member;

the locating member and/or the source member comprising an electrode(preferably comprising a conductive polymer), and a coating thatelectrically surrounds the electrode and which comprises an ion exchangematerial which has an ionic resistance which depends upon theconcentration of a chemical species in the electrolyte;

the connection to the locating member being effective at a first pointwhose location is defined by the presence of the electrolyte;

the making of the connection enabling the formation of a test circuitwhich comprises,

(a) the connection,

(b) that part of the locating member which lies between the first pointand a second point having a known location on the locating member, and

(c) a power source which causes a current of known size to betransmitted between the first and second ponts on the location member;and

the current and locating member being such that, by measuring thevoltage drop between the first and second points, the spatialrelationship between the first and second points can be determined;

(2) the voltage drop between the first and second points is measured;and

(3) the location of the electrolyte is determined from the measurementmade in step (2).

Preferably, the power source is a controlled current source whichdelivers a known fixed current.

The variation of the resistance of the ion exchange material withconcentration of the relevant chemical species preferably occurs asfollows. The ion exchange material may be capable of existing in (atleast) two forms, such as ionized-nonionized, hydrated-nonhydrated, oras (at least) two different combinations of in paris; the postion ofequilibrium betwen the two forms will depend on the concentration of thechemical species under test, for example on pH. In turn, the positoin ofequilibrium will result inthe material having a characteristic ionicconductivity. The skilled man, on reading he present specification willrealize that ionizatino of bound groups of the ion exchange material(for example by dissociation or addition of H³⁰ ) will result inhydration of the bound groups. This binding of water molecules may causethe material to swell, and when swollen and permeated with water it maybecome more ionically conductive.

In order that a change in conductivity of the ion exchange material bemanifest as a change in resistance between two electrodes it ispreferred that the resistance of the material be high compared to otherresistances in series with it (this was addressed above), and also thatthere be no substantial parallel current paths. Thus, the ion exchangematerial preferably surrounds an electrode so that if an electrolytecontacts the electrode it does so only after it has passed through theion exchange material. The material may substantially entirely surroundall surfaces of the electrode, or surfaces not surrounded may beinsulated from the electrolyte. The ion exchange material may be indirect physical contact with an electrode, or it may be bonded theretothrough a layer of an appropriate conductive adhesive. It may,alternatively, merely isolate two electrodes without being in contactwith either although that is not at present preferred.

The invention in it second set of embodiments is of particular value asan acid sensor (ie. for detecting the presence of, or a change inconcetnration of, hydrogen ions), especially as partofa system disclosedin the following patent specifications, the disclosure of each of whichis incorporated herein by reference: EP 0,133,748, U.S. Ser. No.509,897, Masia et al.; U.S. Ser. No. 499,047, Masia et al.; U.S. Ser.No.566,740, Walsey; U.S. Ser. No. 566,829, Walsey; EP0,164,838, U.S. Ser.No. 618,106, Hauptly; U.S. Ser. No. 618,109, Reeder; U.S. Ser. No.618,108, Brooks et al.; U.S. Ser. No. 608,485, Brooks et al.;EP0,160,441; U.S. Ser. No. 603,484, Frank et al; EP0,191,547; U.S. Ser.No. 691,291, McCoy et al.; U.S. Ser. NO. 809,321, McCoy et al.; U.S.Ser. No. 744,170, Stewart et al.; U.S. Ser. No. 787,278, Stewart et al..These specifications together with the present specification will allowthe skilled man to design various systems for location of acid or otherelectrolytes.

In a third set of embodiments there are provided various electrode/ionexchange material combinations, useful for the ion exchange and sensingembodiments described.

Thus, the inventnioprovides an article comprising:

(a) a conductive polymer electrode; and

(b) an ion exchange material in electrical and physical contact withasurface, preferably substantially the entire surface, of the electrode;

the electrode and the material being such that if the article is placedin an electrolyte, sustantially all current passing between theelectrolyte and the electrode passes through the material.

The invention also provides an article comprising:

(a) an electrode, preferably a conductive polymer electrode; and

(b) an ion exchange material affixed to a surface of the electrode byinterpenetration of ion exchange material and electrode material.

The invention also provides an article comprising:

(a) an electrode;

(b) an ion exchange material affixed to a surface of the electrode, theion exchange material being less than 10% swollen with a liquid;

the material being affixed to said surface and the electrode being suchthat when the ion exchnge materialis 100% swollen the ion exchangematerial remains in electrical and physical contact with the electrode.

The invention also provides a bifunctional electrode comprising alaminate of the following layers in the following order:

(a) a cation exchange layer;

(b) a conductive polymer layer (optionally inculding a metallic core);

(c) a conductive polymer layer (optionally including a metallic core);and

(d) an anion exchange layer.

An electrically insulating layer (optionally ionically porous) may beprovided between layers (b) and (c).

The above articles may be made by methods that comprise polymerizing ionexchnge precursors in situ on an electrode, especially on a conductivepolymer electrode. This allows a strong joint to be achieved, allowsinterpenetration, allows thick layers of material to be built up, andallows a material to be formed that is unstressed in its swollen state.

Thus, the invention also provides a method of making an article whichcomprises:

(a) providing an electrode;

(b) contacting the electrode with a liquid ion exchange precursor(preferably monomer); and

(c) polymerizing the precursor, thereby forming an ionically porouslayer in engagement with the electrode.

Polymerization in situ of a liquid precursor may be contrasted with apolymerization method that involves a partial polymerization, andapplication of the resulting gel to an electrode by pressure.

The precursor may have ion exchange functionality, or such afunctionality may be introduced during or after polymerization.

Where the electrode comprises a thermoplastic material, polymerizationis preferably carried out at a temperature above its melt temperature.

The electrode preferably has a surface capable of absorbing ion exchangeprecursors.

The sensing technique of the invention may be used to monitor the pH andtherefore the state of charge of a battery or single cell. A signalproduced by a sensor may be usd to control some electrical or otherdevice that is to be used in conjunction with the cell. For example, thesensor may control a battery charger to prevent unnecessary charging, itmay control a load to prevent excessive discharging, or it may control abattery heater to boost power when the charge is low. Such use,especially control of a charger may be particularly useful in a motorcar or other means of transport.

The invention therefore also provides a cell comprising:

(a) an anode;

(b) a cathode;

(c) a sensor;

(d) an electrolyte in contact with said anode, cathode and sensor, saidelectrolyte containing a chemical species that is involved in anelectrochemical reacton that occurs during operation of the cell, saidsensor having;

(a) a first electrode,

(b) a seocnd electrode, and

(c) a material positioned with respect to said first and secondelectrode such that substantially all current passing between the firstand second electrodes passes through said material;

wherein resistance of said material depends on the concentration of saidchemical species in the electrolyte.

The invention further provides an electrical system that comprises:

(a) a cell comprising:

(i) an anode,

(ii) a cathode,

(iii) an electrolyte containing a chemical species that is involved inan electrochemical reaction that occurs during operation of the cell,and

(iv) a sensor that can provide a signal responsive to the concentrationof said chemical species;

(b) an electrical device that can be electrically connected to the anodeand cathode, or a heater; and

(c) control means that controls operation of the electrical device or ofthe heater in response to a signal from the sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 nad 2 show a series of electrodes for use in ion exchange;

FIG. 3 shows an alternative arrangement using parallel circuit design;

FIG. 4 shows an arrangement employing a single anode and cathode;

FIGS. 5a and 5b show a composite electrode before affixing to anionexchange material;

FIG. 6 shows an electrode together with an ion exchange material;

FIG. 7 shows a first electrode as used for ion sensing;

FIG. 8 shows an alternative first electrode as used for ion sensig;

FIG. 9 shows the electrode of FIG. 7 in combination with a counter, orsecond, electrode for the detection of hydrogen ions;

FIG. 10 shows a sensor apparatus incorporating the electore of FIg. 7;

FIG. 11 is a schemiatic circuit diagram of a circuit incorporating asensing apparatus of the invention;

FIG. 12 shows a response/regeneration curve;

FIG. 13 shows a battery having a sensor therein;

FIG. 14 shows an electrical system; and

FIGS. 15a and 15b show further arrangements of a sensor within abattery.

DETAILED DESCRIPTION OF FIRST EMBODIMENTS OF THE INVENTION

The following description relates to the use of the invention forextraction of a species from an electrolyte, or release of a speciesinto an electrolyte. (Description of the invention relating to sensingwill follow afterwards.)

The species I_(2A) produced by the electrochemical reaction can forexample have the same polarity as, and directly replace, the speciesI_(1A) ; or it can have the opposite polarity and can extract thespecies I_(1A) from the ion exchange resin, thus making it possible fora third ionic species I_(3A) contained in the liquid to replace thespecis I_(1A). In these replacements, and others referred to herein, itis of course possible for ions of the same polarity but different chargeto replace each other, with appropriate adjustment of the number ofions. The speed and completeness of the varous replacements depends uponthe affinity of the ion exchange material for the different ionicspecies, the relative concentrations of those species, the rates ofdiffusion and migration of the species in the material and upon anyelectrochemical forces imposed by an external power source.

The method is particularly efficient when the electrochemical cellfurther comprises (5) a second ion exchange material B which (a)contains an ionic species I_(1B) and (b) is secured to and in electricalcontact with the second electrode at an interface, and anelectrochemical reaction takes place at the interface between the secondelectrode and the ion exchange material and generates an ionic speciesI_(2B) which causes the species I_(1A) to be replaced by another ionicspecies. As at the first electrode, the species I_(2B) can directlyreplace the species I_(1B), or the liquid can contain an ionic speciesI_(3B) which replaces the species I_(1B).

Set out below are the reactoins whic take place in a typical directreplacemet system in which the liquid is H₂ O, the first electrode theanode, the ion exchange material A is a polymer containing coppercarboxylate groups, (PCOO)₂ Cu, and the second electrode is notcontacted by an ion exchange material.

A. In the Anode region

at the interface

    2H.sub.2 O→O.sub.2 +4e.sup.- +4H.sup.+ (species I.sub.2A)

in the ion exchange material

    (PCOO).sub.2 Cu+2H.sup.+ →2PCOOH+Cu.sup.2+ (Species I.sub.1A)

B. In the Cathode region

at the interface

    2H.sub.2 O+2e.sup.- →H.sub.2 +2OH.sup.- (species I.sub.2B).

We have discovered that prior art techniques disclosed in connectionwith ion-exchange reins are often not suitable ofr use in the productionof articles for use in carrying out the method of the present invention.In particular, we have found problems in delamination of resinsfromeletrodes and have found that such problems can be overcome by insitu polymerization of ion-exchange monomers or other precursors.

Thus, in a second aspect the present invention provides a method ofproducing an ion-binding article, which comprises:

(a) providing an electrode, preferably comprising a conductive polymer;

(b) contacting the electrode with a monomer or other ion-exchangematerial precursor; and

(c) polymerizing the precursor, thereby forming a membrane in engagementwith the electrode which engagement can preferably resist membraneswelling.

Preferably the ion exchange material is a polymer comprising unitshaving the general formula I;

    P--R.sub.-- I

wherein P is any organic group as a component of a polymer chain, and Ris one or more functional groups covalently attached to the polymerchain. In one preferred embodiment R is a cation exchange group.Preferably the cation exchange group is selected from the groupconsisting of (i) aminophosphoric acids, (ii) aminocarboxylic acids, and(iii) hydroxamic acids, among others. In another preferred embodiment Ris an anion exchange group. Preferably the anion exchange group isselected from the group consisting of -NR₃ A, -NR₂ HA, -C₅ H₄ NHA, -PR₃A, -SR₂ A, among others.

Preferably the ion exchange material has an oin exchange capacity of atleast 0.1 mequiv/g. More preferably it has an ion exchange capacity of0.5 mequiv/g.

The ion exchange material is preferably coated as a layer ofsubstantially uniform thickness on the electrode. Preferably the layerhas a thickness of at least 1×10⁻⁶ m. More preferably in the range5×10⁻⁵ to 1×10⁻³ m, especially in the range 1×10⁻⁴ to 1×10⁻³ m.Preferably the ion exchange materialcovers substantially the entiesurface of the electrode.

The electrodes may comprise any suitable material. The material of eachelectrode may be the same or different. As example of materials that maybe used there may mentioned (i) metals, for example in the form ofwires, meshes or sheets, (ii) metal or metal oxide particles for examplebonded to a support substrate, (iii) inherently conductive polymers, forexample polypyrolles and (iv) conductive polymers. Preferably theelectrode in each case comprises a conductive polymer.

A conductive pollymer is a mixture of a conductive filler and an organicpolymer (this term being used to include plysiloxanes) thefiler beingdispersed in, or otherwise held together by, the organic polymer. Anysuitable conductive filler may be used, for example, carbon black,graphite, metal or metal oxide particles or a mixture thereof. Documentsdescribing conductive polymer compositions and devices comprising theminclude U.S. Pat. Nos. 2,952,761, 2,978,665, 3,243,753, 3,351,882,3,571,777, 3,757,086, 3,793,716, 3,823,217, 3,858,144, 3,861,029,3,950,604, 4,017,715, 4,072,848, 4,085,286, 4,117,312, 4,177,376,4,177,446, 4,188,276, 4,237,441, 4,242,573, 4,246,468, 4,250,400,4,252,692, 4,255,698, 4,271,350, 4,272,471, 4,304,987, 4,309,596,4,309,597, 4,314,230, 4,314,231, 4,315,237, 4,317,027, 4,318,881,4,327,351, 4,330,704, 4,334,351, 4,352,083, 4,388,607, 4,398,084,4,413,301, 4,425,397, 4,426,339, 4,426,633, 4,427,877, 4,435,639,4,429,216, 4,442,139, 4,459,473, 4,481,498, 4,476,450, and 4,502,929; J.Applied Polymer Science 19, 813-815 (1974), Klason andKubat; PolymerEngineering and Science 18, 649-653 (1978), Nrkis et al; and commonlyassigned U.S. Ser. Nos. 601,424 now abandoned, published as German OLSNo. 1,634,999; 732,792 (Van Konynenburg et al), now abandoned, publishedas German OLS No. 2,746,602; 798,154 (Horsma et al), now abandoned,published as German OLS No. 2,821,799; 134,354 (Lutz); 141,984 (Gotcheret al), published as European Application No. 38,718; 141,988 (Fouts etal), pulbished as European Application No. 38,718, 141,939 (Evans),published as European Application No. 38,713, 141,991 (Fouts et al),published as European Application No. 38,714, 150,9009 (Sopory),published as UK Application No. 2,076,106A, 184,647 (Lutz), 250,491(Jacobs et al) published as European Appliction No. 63,440, 272,854 and403,203 (Steward et al), published as European Patent application No.67,679, 274,010 (Walty et al), 300,709 and 423,589 (Van Konynenburg etal), published as European Application No. 74,281, 369,309 (Midgley etal), 483,633 (Wasley), 493,445 (Chazan et al), published as EuropeanPatent Application No. 128,664, 606,033, (Leary et al), published asEuropean application No. 84,305,584.7, 534,913 (McKinley), 535,449(Cheng et al) published as European Application No. 84,306,456.9,552,649 (Jensen et al) published as European Application No.84,307,984.9, 573,099 (Batliwalla et al) and 904,736, published as UKPatent Nos. 1,470,502 and 1,470,503, and commonly assigned applicationsSer. Nos. 650,918 (Batliwalla et al), 650,920 (Batliwalla et al,continuation-in-part 663,014 (Batliwalla et al), continuation-in-part735,408 (Batliwall et al), 650,919 (Batliwalla et al, 650,921 (Kheder),711,790 (Carlomagno), 667,799 (Frank), 711,908 (Ratell), 711,907(Ratell), 711,909 (Deep et al), 720,118 (Soni et al), and 711,910 (Au etal). The disclosure of each of the patents, publications andapplications referred to above is incorporated herein by reference.

In one embodiment the electrode comprises a conductive polymer, andhteion exchange mterial comprises a polymeric material which has beenbonded to the electrode surface in such a manner that there is produceda layer of a polymer blend between electrode and mterial which is atleast 1 optically at least 5 microns thick. The polymer blend layer is ablend of the polymer of the ion exchange material or the ion exchangematerial percursor and the conductive polymer of the electrode.

The electrodes may be any shape. In a preferred embodiment theelectrodes are planar. In another preferred embodiment the electrodesare cylindrical.

Preferably the electrode has an elastic modulus less than 10¹³dynes/cm², and it is preferably solid in cross-section.

A particularly preferred embodiment of the invention when used for ionremoval comprises a plurality of electrodes, preferably planar, whic arearranged in a stack, that is with each face of an electrode facing aface of its adjacent electrode. In the stack each electrode ispreferably a bipolar electrode, that is one of its faces behaves as ananode and the other of its faces behaves as a cathode. With thisarrangement each adjacent pair of electrodes functions as a cell whichcan effect ion extraction and expulsion. Thus for a stack of bipolarplates the capacity for ion exchange and expulsion is approximatelyn×capacity of a single anode/cathode cell.

Referring now to the drawins, FIGS. 1 and 2 show a stack of electrodes 2supported in a casing 4 by insulating supports 6. Each electrode isplanar and is arranged substantially parallel to its neighbor. Theoutermost eletrodes (that is those nearest to the casing side) areconnected to a DC power source 8. As illustrated in FIG. 1 the electrodeon the right of the drawing is connected to the negative terminal of thepower soruce, and the electrode on the left of the drawing is connectedto the positive terminal of the power source. A liquid 10 contsaining anionic component (MA) is recycled through the casing as shown by thearrows. The inlet and outlet for the liquid 10 are at opposite ends ofthe casing 4. Thus the liquid 10 passes over each electrode 2. Theliquid 10 contains a number of ionic species. From the liquid, cation M⁺and anion A⁻ are to be extracted.

Each electrode 2 is a bipolar electroe, that is one of its surfacesbehaves as an anode (oxidation occurs at its surface), and theother ofits surfaces behaves as a cathode (redution occurs at its surface). Eachelectrode comprises a condutie polymer core, which may include ametallic current collector. The outermost electrodes are coated on theirinward facing surfaces with anion exchange material. The centraleletrodes are coated on both their surfaces with an ion exchangematerial. All those surfaces facing one direction (to the left asillustrated) are coated with a weak acid cation exchange material PCOOH12, (in which the exchangeable ion is H⁺). All those surfaces facing inthe opposite diretion (to the right as illustrated) ar coated with aweak base anion exchange material PNR₂ 14. The cation exchange materialPCOOH has a greater affinity for M⁺ than for any ofthe other catoins insolution 10. It also has a greater affinity for H⁺ ions than for M⁺ions. The weak base anion exchange material has a greater affinity forOH⁻ ions than for A⁻ ions. With the power source connected as shown, theleft facing surface of each electrode behaves as a cathode, and theright facing surface of each electrode behaves as an anode. Thus asereies current passes between the outermost electrodes. As current ispassed the following reactions occur at each anode and cathode surface,and in the ion exchange materials.

Cathode

    2H.sub.2 O+2e.sup.- →2OH.sup.- +H.sub.2             (A)

In cation exchange material 12 at teh cathode

    PCOOH+OH.sup.- →PCOO.sup.- +H.sub.2 O               (A.1)

    PCOO.sup.- +M.sup.+ →PCOOM                          (A.2)

Anode

    2H.sub.2 O→4H.sup.+ +O.sub.2 +4e.sup.-              (B)

In anion exchange mateiral 14 at the anode

    PNR.sub.2 +H.sup.+ +A.sup.- →PNR.sub.2 HA           (B)

Thus ions M⁺ and A⁻ are extracted fromliquid 10.

The extracted ions M⁺ and A⁻ may then be expelled into a liquid. To dothis the liquid 10 may be replaced by pure water, and the eletricalconnections to the power source reversed. With thereversed connectionseach surface coted witha cation exchange material now behaves as ananode, and each surface coated with an anion exchange resin now behavesas a cathode. As current is passed the following reactions occur at eachcathode and anode surface.

Anode

    2H.sub.2 O→4H.sup.+ +O.sub.2 +4e.sup.-              (C)

In cation exchange material at the anode

    PCOOM+H.sup.+ →PCOOH+M.sup.+                        (C.1)

Cathode

    2H.sub.2 O+2e.sup.-→ 2OH.sup.- +H.sub.2             (D)

In anion exchange material at the cathode

    PNR.sub.2 HA+OH.sup.- →PNR.sub.2 +H.sub.2 O+A.sup.- (D. 1)

Thus ions M⁺ and A⁻ are expelled into the new solution. Becuase thecation exchnge material has a greater affinity for H⁺ ions than M⁺ ionsreaction C.1 above is strongly biased on the forward direction.Similarly, reaction D.1 is strongly biased in the forward direction.Thus the expulsion or "elution" of MA is very efficient.

Ion exchange is more efficient than previous methods employing chemicalor electrical regeneration because all H⁺ and OH⁻ "eluant" must passthrough the ion exchange layer bonded to the electrode. In contrast, thepassage of eluant through any system using ion exchange resin beads, asin the prior art, leaves open the possiblity that eluant ions willbypass many beads. This is a particular possiblity when the ion exchangematerialexhibits a large ionic resistance, for example when the beads donot swell considerably. The present inveniton (unlike some of the priorart sytms employgin electrochemical regerneraton, eg. U.S. Pat. No.4,032,452, Davies) can allow the use of ion exchange layersand solutionsof a broader range of resistivities. The present invention in particularcan allow the useof low or high resistivity solutions regardless of theresistivity of the ion exchange layer. When copared to chemicalregeneration, the methods of regeneration disclosed herein benefit fromthe economy,safety, cleanliness and convenience achievable withelectrical regeneration.

The M⁺ ions can be extracted from liuqid 10, using the apparatus shownin FIG. 1,by an alternative method.In that alterntive method liquid10ispreceded by another ionic solutin, for example a sodium chloride (NaCl)solution, and the apparatus electrically powered as shown. Reactionscorresponding to (A) and (B) occur in a sodium chloride solution suchthat the ion exchange material becomes PCOONa and the an ion exchangematerial becomes PNR₂ HCl. Then the sodium chloride solution is replacedby liquid 10 containing the M⁺ and A⁻ ions, with power source 8disconnected. Since hecation exchange material PCOO⁻ has a greateraffinity for M⁺ than for Na⁺ ions, the following passive exchangereaction occurs spontaneously:

    PCOONa+MA→PCOOM+NaA

The extracted M⁺ ions are then expelled into solution in the mannerdescribed above.

The alternative method is particularly preferred where the cationicspecies to be extracted is one which is liable to be reduced to a metalor precipitate at the cathode surface during the powered extractionprocess.

FIG. 3 shows an alternative arrangement illustrating a parallel circuitdesign. Each bifunctional electrode 30 is substantially planar andcomprises five layers. The five layers are fromleft to right, cationexchange layer 32, conductive polymer 34, insulating core 36, conducivepolymer 34,and anion exchange layer 38. Each conductive polymer layer isconnected to a power supply 8. The conductive polymer layer may includeametallic current collector. As in the series circuit, each electrode isarranged such that all the surfaces facing in one direction behave asanodes an all the surfaces facing in the other direction behave ascathodes. Liquid 10 is fed into the casing 4 as in the embodimentillustrated in FIGS. 1 and 2. Thus a series of parallel electrochemicalcells are produced. Equivalent extraction and expulsion processes tothose described with reference to FIGS. 1 and 2 can be carried out.

FIG. 4 shows an alternative device inwhich ghere is only one anode andcathode, or allanodes and cathodes form a single structure. Alayeredstrip is prepared. The strip comprises four elements (1) a conductivepolymer electrode 42 coated on one surface with ananion exchangematerial, (2) a mesh spacer 44, and (3) another conductive polymerelectrode 46 coated on one surface with a cation exchange material, and(4) an insulating layer shown in dotted outline, 48. The conductivepolymer electrodes are positioned so that the ion exchange materialcoatings face each other and are separated by the mesh spacer. The stripis sealed at its edges and ends, and a soution (from which ions are tobe extracted, or into which ions are to be expelled) is fed into thestrip between the ion exchange materials, for example into the porousend-piece 49. The conductive polymer layers comprising currentcollectors are connected to the terminal of a power supply so that onebehaves as an anode and the other as a cathode. Extraction and expulsionreactions equivalent to those described with reference to FIGS. 1 to 3occur at thecathode and anode surfaces. The ion exchange occurs alongthe length of the strip. The strip is spiralled so that it is aconvenient shape and size, and the insulating layer prevents shortingbetween the two electrodes.

A preferred method will now be described of making an ion-bindingarticle, suitable for use in the method of replacing an ionic speciesdescribed above. This preferred method allows an ion-exchange materialto be attached to an electrode sufficiently securely that swellingforces, resulting for example from the immersion of a dry or less than100% solvated article in a solution, for exaple an aqueous solution,maybe resisted. In general, one or more monomers or other ion-bindingresin precursors are polymerized insitu, ie. in contact with anelectrode. The precursor may have ion-exchange functionality before itis brought in contact with the electrode, functionality may beintroduced during polymerization, or functionality may be introducedafter polymerization is complete.

It is preferred that the electrode in contact with monomers or otherprecursors be capable of absorbing one or more of the precursors. It isalso preferred that the electrode comprise a thermoplastic mateiral, forexample a conductive polymer, especially a polymer having carbonn blacktherein. Absorption of the precursor, we have found, can result in abond betwen the electrode and the resulting ion-exchange resin that issurprisingly strong. It is believed that this bond has the nature of aninterpenetrating network. The bond region may penetrate the surface ofthe electrode to a distance from, say, 10⁻⁷ to 10⁻⁷ to 10⁻³ m,preferably 10⁻⁷ to 1×10⁻⁴ m. The depth achieved in practice willdependon the solubility of the precursor in the electrode material, and on thetemperature at which polymerization is carried out. Thus, thetemperature, the precursor and electrode mateials (and thus thesolubility of one inn the other) may be varied to achieve the desireddepth of interpenetration, and thus the desired bond strength.

Two examples may be given. Firstlyl, an electrode comprising a compositeof metalwire and SCLAIR 11W plus carbon was pentrated to a depth ofabout 5×10⁻⁵ m by a polymerizing liquidmonomer polymerized at atemperature 20° C. above the T_(m) (melt temperature) of the electrodecomposite. Secondly, a depth of pentratin of abot 1×10⁻⁴ m was achievedin the case of an Elvax 360/carbon electrode composite and a liquidmonomer polymerized at 40° C. above T_(m).

Successful results can be obtained where the polymerization tempeatureis below T_(m) but the bond depth is likely to be small. At such lowertemperatures, the solubility of the precursor in electrode materialbecomes more important.

Examples of methods of preparing ion-binding electrode articles may nowbe given to illustrate the three possiblities, mentioned above, astowhen ion-exchange functionality is introduced.

Which route is chosen for the introduction of functionality will, ofcourse, depend on the functional group desired and on the chemicalnature of the electrode and polymer backbone of the ion-exchange resin,and on any solvent employed. It may, also, however, depend on otherbehavior of the various chemical species, for example on thesolubilities of the species in a common solvent such as a coatingsolution, and upon the solubility of the various possible precursors inthe electrode material.

In many cases, it may be desirable to carry out the polymerization orthe introduction of functionality in a different solvent from that inwhich the final ion-binding articles will be used. For example, asolvent such as methyl ethyl ketone may be used for reactions such asthe production of fully quaternized resins, whereas the final productmay be used in aqueous solution. Swelling in non-aqueous solvents, andexchange of one solvent for another during preparation of these articlesis likely to put considerable stress on the bond between theion-exchange material and the electrode. The strong engagement with theelectrode that we are able to achieve through absorption and in situpolymerization, particularly of monomer precursors, is advantageous inthis respect.

Embodiments of the invention will now be described in the followingexamples.

EXAMPLE 1

An electrode 56 before bonding to an ion exchange membrane, is 3.3 cmwide, 6.0 cm long and 0.3 cm thick. It is illustrated in FIG. 5 and itconsists of three mateials, a conductive polymer blend of 41.,8%graphite (GP-39, trademark), 12.6% carbon (Conductex 975, trade mark),and 43.5% base polymer 51 and 52, an aluminum mesh current collector 53,and unfilled base polymer for insulation 54 and 55. The insulatingmaterial is positioned such that only ne face of conductive polymer 51,the active electrode surface, is exposed upon immersion in a liquid, andthe curent collector is placed betwen the conducive polymer faceopposite the exposed face and the insulating layer. The aluminum meshand insulating layer extend above the active electrode surface 51 toconductive polymer 52 to provide a place for the electrical connection.

The conductive polymers 51 and 52 are both in electrical contact withaluminum mesh 53 and are separated by a 1 cm wide insulating polymerstrip 55.

The ion exchange material may be deposited in one step by employing amonomer possessing the desired ion exchange functionality. Electrode 56was heated on a hot plate to 135° C. for 3 min. and 0.25 g of a solutionof 47.43 weight percent 2-ethylhexyl acrylate, 45.90% 4-vinylpyridine,3.49% technical divinylbenzene (55% grade), and 3.18% t-butylperoctoateadded dropwise to cover the surface of the exposed face of theconductive polymer. The electrode was then covered with a shallow dishto contain vapors and left at 135° C. for 10 min., when it was removedand allowed to cool. This was swollen in 1 M HCl to form the pyridiniumchloride form of the ion exchange material.

EXAMPLE 2

Rather than using a functional monomer as in Example 1, the ion exchangefunctionality may be incorporated during the polymerization. Electrode56 was heated to 120° C. on a hot plate for 3 min. , and 0.56 g of asolution of 37.75 weight 5 vinylbenzylchloride, 7.5% 4-vinylpyridine,4.2% technical divinylbenzene, 1.3% t-butylperoctoate, and 50%1-methylnapthalene (an inert diluent) added dropwise to cover thesurface of the exposed face of the conductive polymer. The electrode wasthen covered with a shallow dish to contain vapors and left at 120° C.for 6 min., when it was removed and allowed to cool. After soaking thearticle for 24 hours first in 50/50 methylethyl ketone/methanol then inwater, the article could be placed in 1 M HCl to form the pyridiniumchloride form of the ion exchange material.

EXAMPLE 3

This article was prepared as in Eample 2 but a monomer solution of 30.66weight percent 4-viylpyridine, 12.86% vinylbenzyl chloride, 5.0%technical divinylbenzene, 1.48% t-butylperoctoate, and 50%1-methylnapthalene was added dropwise to the electrode 56 heated to 120°C.

EXAMPLE 4

A hydrophobic layer containnig anoin exchange precursor may be attachedto electrode 56 as described in Example 1, and subsequently reacted inone or more steps to introduce the ion exchange group. In this example atwo step functionalization process is required to produce a waterswellable ion exchange layer with high capacity for copper ion.Electrode 56 was heated to 135° C. on a hot plate for 3 min. and 0.25 gof a solution of 91.4 weight percent vinylbenzyl choride, 6.2% technicaldivinylbenzene, and 2.4% t-butylperoctoate added dropwise to cover theexposed face of the conductive polymer. This was covered with a shallowdish to contain vapors, left at 135° c. for 10 min., and allowed tocool. The weight of the ion exchange precursor layer was determinedgravimetrically, and found to be 0.20 g.

Twenty percent quaternization, based on vinylbenzyl chloride, wasintroduced by using enough dimethylethylamine to reat with 30% of thevinylbenzyl chloride gorups (one-third ofthis reagent does not react).This functionality is required to provide adequate water swellabilityand to allow the introduction of sufficient sarcosine functionality inthe following step. The article witha 0.20 g layer (possessing 0.128 gvinylbenzyl chloride) was therefore swollen in a mixtue of 200 mlmethylethyl dketone and 0.026 g dimethylethylamine for 2 hoursthenheated at 40° C. for 16 hours. After stirring in water several hoursthe article could be treated with 1 M KBr to exchange bromide forchloride. The realtive intensities of the bromide and chloride peaks inan X-ray fluorescence spectrogram confirmed that 20% of the vinylbenzylchloride groups had been quaternized.

The 20% quaternized article, with or without the KBr exchange step, wasfunctionalized with sarcosine by placing it in a solutionof 18.3 gsodium sarcosinate, 180 ml methanol and 120ml water, stirring 20 hours,and then heating at eflux for 16 hours. Aftr cooling to roomtemperature, 165 ml. of 1 M HCl was added slowly, and the article rinsedin water. The copper capacity of this ion exchange layer was measured bystirring in 1 M CuCl₂ for 2 hours, rinsing for 2 hours, and finallyextracting the copper in 1 M HCl. The absorbance ofthe HCl solutino at788 nm was used to calculate the copperion concentration with Beer's law(using an extinction coefficient of 11.4), and this article was found tohave a copper capacity of 0.76 mmoles Cu/g ion exchange layer (based onan ion exchange precursor layer weight of 0.20 g.).

EXAMPLE 5

This is a further example of introduction of the sarcosine ion exchangefunctionality following the polymerization of the monomers. The articlefrom Example 2 (without the HCl treatment) was placed in a solution of18.3 g sodium sarcosinate, 180 ml. methanol and 120 ml. water, stirredfor 2 hours at room temperature, then heated at reflux for 16 hous. Themixture was cooled to room temperature, 165 ml. of 1 M HCl added slowly,and the article rinsed in water for 16 hours. After stirring in 1 M KOHfor 2 hours, water for 2 hours, 1 M CuCl₂ for 2 hours,and finally waterfor 2 hours, the copper ion capcaity was measured by extraction of thearticle with 1 M HCl and measurement of the solution absorbance usingvisible spectroscopy. The copper capacity was found to be 0.90 mmolesCu/g ion exchange material.

EXAMPLE 6

FIG. 6 shows a first electrode 62 as described in Example 4 with the ionsarcosine exchange layer 63 in the copper form placed in a 3.5 cm wideby 5.5 cm high by 1.3 cm wide plexiglass cell 64 facing a secondelectrode 66 without an ion exchange layer, and11.0 ml 0.1F NaClO₄liquid electrolyte added immediately to level 67 just above the top oflayer 63. Powered expulsion of copper (II) was effected by connectingthe two electrodes through silver painted conductive polymer tabs 68 toa constant current poer supply 69 with the first electrode 62 as theanode. A current of 1mA/cm² (6mA total) was appllied for 80 minutes,passing a total of 1.4 mmole electrons/g ion exchange layer andproviding 1.5 mmole H⁺ /g via the electrochemical oxidation of water.(Two H⁺ are required for each copper (II) originally in the ion exchangelayer.) The direct electrochemical expulsion of Cu(II) is represented bythe following reactions:

    2H.sub.2 O→4H.sup.+ +4e.sup.- +O.sub.2              (a)

    (Psarc).sub.2 Cu+2H.sup.+ →Cu.sup.+2 +PsarcH        (b)

Psarc in reactin b represents the sarcosine functionalized in the ionexchange layer. A light blue Cu(OH)₂ precipitate forms duringhteexpulsion. The power supply was disconnected and the cell left to restfor one hour. The electrodes 62,66 were removed and the quantity ofcopper expelled calculated directly from the copper found as Cu(OH)₂precipitate, and by difference after measuring the copper remaining inthe ion exchange mateiral on electrode 62. The Cu(OH)₂ solid wasdissolved by adding 1.0 ml 1.0 M aqueous HCl, and the copperconcentration measured by visible spectroscopy. The copper remaining intheion exchange layer after expulsion was measured as before for thecapacity measurement by extraction with 1 M HCl.

For this example both measurements found the efficiency of copper (II)expulsion to be 20%, defining this quantity as 100×(2×moles copperexpelled/moles electrons passed).

EXAMPLE 7

The electrode article prepared in Example 5, with the copper sarcosinateion exchange material (the first electrode 62) and the article preparedinExapmle 3, with the pyridinium chloride material (the second electrode66) were placed in the plexiglass cell 64 of FIG. 6, again with theactive electrode surfaces 51 facing each other, and 11.0 ml 0.1F NaClO₄liquid electrolyte added immediately. Powered expulsion was effected byconnecting the first electrode 62 in the copper form to the positiveterminal of a constant current power supply 69, and the second electroe66 in the proton form to the negative terminal. A current of 1mA/cm²(6mA total) was applied for 96 minutes, passing a total of 1.8 mmoleeletrons/g ion exchange material and providing 1.8 mmole H⁺ /g to thefirst electrode 62 (2H⁺ are required for each Cu(II)). The direct Cu(II)expulsion at the first electrode is as described in example 6. Theindirect chloride expulsion at the second electrode is represented asfollows:

    2H.sub.2 O+2e.sup.- →2OH.sup.- +H.sub.2             (c)

    P.sub.py HCl+OH.sup.- →P.sub.py +H.sub.2 O+Cl.sup.- (d)

P_(py) inreaction d represents the pyridine (py) functinalized in theion exchange layer. The copper (II) was expelled into the liquid assoluble CuCl₂ rather than the solid Cu(OH)₂ in example 1 because the OH⁻produced via water reduction at the second electrode 66 in reaction Creacts with the pyridinium chloride group of the second ion exchangelayer.The cell was disconnected and left to rest for one hour, and thequantity of expelled copper (II) measured as in Example 6. Theefficiency of copper (II) expulsion in this experiment was 98%.

DETAILED DESCRIPTION OF SECOND EMBODIMENTS OF THE INVENTION

The following description relats to sensing a chosen chemical speciesand to control of operation of a battery or single cell. A sensor maycomprise first and second electrodes to which a power source isconnected, and an ion exchange material attached to at least one of theelectrodes, or othewise separating them. The sensor will in general,therefore, function as an electrolytic cell.

When a power source is connected to the electrodes of the sensor cell, acurrent flows between the electrodes, the magnitude ofthe currentdependig on (as hereinbefore defined) the concentraitonofhte chemicalspecies in the liquid. In one embodiment, using a particulr ion exchangematerial, in the substantial absence of the chemical species a nominalor trickle current flows, of the order of 10⁻⁸ A/cm², and in thepresence of chemical species in concentrations of 10⁻³ M (the thresholdvalue) or greater a significant current flows, of the order of 10⁻⁴A/cm². These curent and threshold concentration quantities depend atleast in part on the ion exchange material employed, and may vary bymany orders of magnitude when using alternative ion exchange materials.The change in the current flow is explained as follows. When the ionexchange material is in the presence of the chemical species it exhibitsa lower ionic resistance. At each electode surface an electrochemicalreaciton takes place, electrons being provided for chemical reduction atthe cathode and consumed in chemical oxidatins at the anode. Thus, inthe presence of the chemical species it exhibits a lower ionicresistance. At each electrode surface an electrochemical reaaction takesplace, electrons being provided for chemical reduction at thecathode andconsumed in chemical oxidations at the anode. Thus, in the presence of asufficient concentration of chemical species, that is a concentrationexceeding the threshold value, a more active electrochemical cell isformed, and alarger electrical current flows betrween the electrodes.The speed with which the cell current increases depends upon theconcentration of the chemical species, that is upon the degree to whichthe concentration exceeds the threshold level, 10⁻³ M in this example.Thus the cell current incrases fater for greater chemical species'concentrations. In this example, for a concentratn of 10⁻¹ M, the cellrequires an hour before passing 10⁻⁴ A/cm², and for same currentdensity. In contrast, in the absence of the chemical species the ionexchange material exhibits a greater ionic resistance. Thus a lessactive electrochemical cell is formed and a smaller, or only a trickle,electrical current flows between the electrodes.

The first and second electrodes may comprise any suitable condutivematerial. The two electrodes may comprise the same or differentmaterials. As example of materials that may be used ther may mentioned(i) metals, for example in the form of wires, meshes or sheets, (ii)metal or metal oxide particles for example bonded to a supportsubstrate, (iii) intrinsically conductive polymers, for examplepolypyrolles, and (iv) conductive polymers. Preferably one or bothelectrodes in each case comprises a conductive polymer which forms atleast part of the surface of the electrode.

The electrodes may be any shape. The two electrodes may be the sameshape or a different shape. In one preferred embodiment one, orpreferably both, electrode is elongate, for example in the form of awire. In another embodiment the, or each, electrode is substantiallyplanar, for example in the form of a flat plate.

The ion exchange material is arranged so that substantially all currentpassing through the electrochemical cell passes through the ion exchangematerial. The preferred positinoing of the ioon exchangematerialrequired to achieve this result depends inter ali o the sahpe ofthe electrode. For an electrode inthe sahpeof a wire, the ion exchangematerial preferably covers the entire curved surface of the wire, inorder completely to separate the electrode from the chemical species.For an electrode in the shape of a flat plate, the ion exchange materialis preferably bonded to noe or to both of theflat surfaces of theelectrode, depending onn how the electrode is to be exposed to theliquid. If the liquid forms one wall of a bath containing theelectrolyte only one surface (the inner facing surface) need be covered.If the electrode is immersed in the bath, preferably both surfaces arecovered, at least to be the electrolyte level.

In preferred embodimens when the ion exchange material is exposed to thechemical species it swells by absoring some or all components of thelqiuid. In this case the first electrode is preferably extensible sothat it can comply with that swellig. The term "comply" is used heriento mean that the electrode can extend such that the bond between theelectrode and the ion exchange materialis not damaged by the swelling.Preferably the peel strengths of the bond betwe the electrode and theion exchange material when the ion exchange maerial is in itspre-swollen and swollen state are equal to, or exceed, the tensilestrength of the electrode itself. For this reason inter alia it ispreferred to use conductive polymers for the electrodes since thosepolmers typically can be extended without adversely effecting theirelectrical properties. In preferred embodiments the liquid used isaqueous.

Preferably the ion exchange material is provided as a layer. The layerpreferably has a minimum thickness of 1 micron, preferably 20, morepreferably 50, especially 100 microns. The preferred maximum thicknessmay be 1000 microns or more. More preferably the thicknes is in therange 50 microns to 1000 microns, typically 50-300 microns.

For some applications, theino exchange mateira is preferablycrosslinked. Crosslinking may be effected by chemical means, or byirradiation, for example with a beam of fast electrons or gamma rays.Crosslinking 02-20 mol %, especially 0.5-6 mol %, is preferred.

The electrode is preferably flexible bywhich is meant that at 23° C. itcan be wrapped around a 4 inch (10 cm) mandrel, preferably 1 inch (2.5cm) mandrel, without damage.

The ion exchange material may comprise any suitable polymer which onexposure to the chemical species changes, preferably decreases, itselectical resistance. Perferably the ion exchange mateiral comprises apolymer comprising a plurality of repeating units having the generalformula I

    P--R                                                       (1)

wherein P is an organic polymer group, and R is a functional group whichrenders the ion exchange mateiral more ionically conductive in thepresence of the chemical species. R is typically a neutral functionalgroup in the less conductive state, and a charged group in the moreconductive state. the polymer may be a branched or straight-chainpolymer selectd from the group comprising a homopolymer, a copolymer, aterpolymer anda blend of such polymers.

Preferred embodiments of the invention can be used to detect changes inconcentration of hydrogen ions, i.e. acid. In these cases the firsteletrode may be made either the cathode or the anode in theelectrtochemical sensor cell. Certain advantages are achieved when thefirst electrode is made the cathode, and other advantages are achiefedwhen the first electrode is made the anode. In one embodiment, for anacid sensor, in the absence of a sufficient concentration of hydrogenions and in exchange mateiralhas a low ionic conductivity, passing only10⁻⁸ A/cm². After the ion exchange material has contacted hydrogen ions,10⁻³ M or greater in this example, it becomes muchmore conductive,pawsing 10⁻⁴ A/cm². Thus when an aqueous liquid containing a sufficienthydrogen ion concentration is introduced between the electrodes a moreactive electrochemical sensor cell is formed (i.e. a greater currentpasses between the electrodes).

As an example of the invention, the electrochemical reactions whichtypically occur at the cathode and anode surfaces, giving rise topassage of the electrical current, are given for an acid sensor in anaqueous liquid, the first electrode is the cathode and the secondelectrode is the anode.

    Cathode: 2H.sub.2 O+2e.sup.- →2OH.sup.- +H.sub.2 (g)(1)

    Anode: 2H.sub.2 O→4e.sup.- +4H.sup.+ +O.sub.2 (g)   (2)

A larger electrical current flows between the electrodes in the presenceof hydrogen ions as a result of the layer's ionic resistance decreasing.Typically the total measured current is of the order of 10⁻⁵ to 10⁻³ A.Depending on the materials used, the sensor cell may indicate simplywhethe the pH is aboe or below a certain value, or it may be able togive quantitative information over a range of pH values.

For detecting the presence of hydrogen ions, it is preferred that theion exchange material comprises basic functinal grups R which uponreaction with hydrogen ions causses a decrease inthe ionic resistance ofthe ion exchange material. This functional group R is typically aneutral basic group which becomes charged upon reaction with a hydrogenion. More particularly it may be selected from the family of nitrogencontaining bases. These may be primary, secondary, or tertiary alkyl oraryl substituted amines, substituted and unsubstituted nitrogencontaining heterocyclics, amides, or any other group which causes theion exchange mateiral to become more ionically conductive in thepresence of hydrogen ions. For detecting the presence of an acid, theion exchange material preferably has an acid dissociation factor pK_(a)in the range 0 to 6. It is this quantity which determines the thresholdvalue mentioned earlier. A smaller pK_(a) material requires a greaterconcentration of acid for detection.

In one preferred embodiment for use with aqueous liquids the ionexchange material comprises pyridine (--C₅ H₄ N) as the functioal groupR. That polymer becomes more ionically conductive in the presence ofhydrogen ions as a result of the following reaction:

    P-C.sub.5 H.sub.4 N+H.sup.+ →P-C.sub.5 H.sub.4 NH.sup.+

The formation of the pyridinium group )P-C₅ H₄ NH⁺) is accompanied byswelling of the polymer, due to absorption of water.

Other preferred embodiments of the invention can be used to detect thepresence of chemical bases (e.g. hydroxide, ammonia, carbonate). Inthese cases the first electrode may be made either the anode or thecathode, there being different advantages to each arrangement. After theion exchange material has contacted the basic solution, it becomes moreionically conductive. Thus when a basic aqueous solutin containinghydroxide ions, for example, is introduced betwen the electrodes, theionic rsistance of the ion exchange material decreases and a more activeelectrochemical cell is formed. For a base sensor in which the firstelectrode is made the anode and the second electrode the cathode,reactions (1) and (2) above typically take place at tehcathode ad anodesurface as in the case of the acid sensor. Thus upon exposure tohydroxide ions the current passed between the electrodes increases.Typically that measured current is of the order of 10⁻⁵ to 10⁻³ A.

For detecting the presence of basic solutions, it is preferred that thepolymer coating comprises acidic functional groups R which upon reactionwith a base causes the ion exchantge material to become more ionicallyconductive. This functional group is typically a neutral acidic groupwhich becomes charged upon reactino with chemical bases. Moreparticularly it may be selected from the families of carboxlic acids,diketones, oximes, phenols, or any other grou which causes the ionexchange mateiral to become more conductive in the presence of hydroxideions. For detecting the presence of a base, the ion exchange materialpreferably has a dissociationfactor pK_(a) of 8 to 14. In this case agreatet pK_(a) mateiral rquries a larger concentration of base fordetection.

In one embodiment the ion exchange material comprises carboxylic acid asthe functional group R. The crboxylic acid gropups cause the ionexchange material, P--COOH, to become more conductive in the presence ofbasic solutions as follows, using hydroxide as an example: ##STR1##

When the relevant chemical species from the liquid contacts the firstelectrode, generally after being absorbed by and after passing throughthe ion exchange material, itmay undergo an eelctrochemical reaction atthe electrode surface. Another chemical species will undergo anotherchemical reaction at thesecond electrode surface, thus allowing thepassage of current. In preferred embodiments for detecting hydrogen ionsin an aqueous liquid, when water contacts the first electrode as acathode it reacts to produce hydroxide ions (Reaction (1)). Similarly ina preferred embodiment for detecting basic solutions in aqueoussolution, when water contacts the first electrode as an anode it reatsto produce hydrogen ions (Reaction (2)). Preferably the ion exchangematerial is positioned at that electrode where the products of theelectrochemical reaction are those which will drive the ion exchangematerial back to its less conductive state. For example, for thedetection of hydrogen ions when the in exchagne material comprises apolymer comprising units having the general formula P--C₅ H₄ N, the ionexchange mateiral should be positioned at the cathode. The reacationsthat take place are as follows:

    P--C.sub.5 H.sub.4 N+H.sup.+ →P--C.sub.5 H.sub.4 NH.sup.+ (3)

    At cathode: 2H.sub.2 O+2e.sup.- →2OH.sup.- +H.sub.2 (g)(4)

    P--C.sub.5 H.sub.4 NH.sup.+ +OH.sup.- →P--C.sub.5 H.sub.4 N+H.sub.2 O(5)

Similarly for the detection of basic solutions, such as hydroxide,wherein the ion exchange mateiral comprises a polymer having the generalformual P-COOH (in its less conductive state) the reactions are asfollows:

    P--COOH+OH.sup.- →P--COO.sup.- +H.sub.2 O           (6)

    At anode: 2H.sub.2 O→4e.sup.- +4H.sup.+ +O.sub.2 (g)(7)

    P--COO.sup.- +H.sup.+ →P--COOH                      (8)

Thus the less conductive state of the in exchange material isregenerated when the relevant chemical species is substantially absent.That is, upon removal of substantially most of the chemical species theless conductive state of the ion exchange material is reformed, as longas a liquid electrically bridges the two electrode. By substantiallyabsent is meant that the concentration of the chemical species is belowthe threshold level. This advanageously means that continuous monitoringof the chemical species is possible. If regeneration did not take place,and if no other steps were taken and if no otehr reations were takingplace, once all of the oin exchange material had been converted to itsmore conductive state the sensor cell would thereafter respond to anyconductive solution, and would not selectively detect the chemicalspecies with which we are concerned.

As mentioned above in connection with the acid and base sensors, thefirst electrode may be either the anode or the cathode; but to ensureregeneration of the ion exchange material the first electrode ispreferably the cathode in the acid sensor, and the first electrode ispreferably the anode in thbas sensor. For applications whereregeneration is not required, it may be preferred to reverse thepolarities of the electrodes, viz so the first electrode is the anode inthe acid sensor, and the cathode in the base sensor. With thesearrangements reactions (3) and (6) are facilitated since hydrogen andhydroxide ions respectively are produced at the first electrode surfaceby reactions (2) and (1)). Thus the ion exchange material onn the firstelectrode in its less conductive state can react not only with hydrogenand hydroxide ions from the aqueous liquid, but also with those ionsproduced by electrolysis of water at the first electrode surface. Thusthe ion exchange material becomes more conductive faster, and thus thesensor exhibits a shorter response time. In some embodiments accordingto the invention it is preferred to change the polarity of theelectrodes part way through the detection. Preferably the polarity ischanged so that first a rapid detection is achieved, and thenregeneration. In other embodiments it is preferred to alternate thepolarities of the electrodes on a regular cycle, for example by imposinga sinusoidal or square AC signal, or by powering the two electrodes withshort voltage pulses, followed by a period during which the electrodesare left open circuited.

To detect an acid, the ion exchange material preferably comprises afunctional group that has a dissociation factor, pK_(a), which isnumerically the same as, or greater than the pH of the solution to bedetected. This achieves maximum conversion of the ion exchange materialto its more conductive state. Similarly, the ion exchange material for abase sensor comprises a functional group that has a pK_(a) numericallythe same as, or less than, the pH of the liquid tobe detected.

Preferably the electrochemical sensor cell comprises a second ionexchange material positioned in contact with the liquid, such thatsubstantially all the electrical current passing through theelectrochemical cell to the second electrode pases through the secondion exchange material. The electrical resistance of the second ionexchange material is preferably lower in the presence of the chemicalspecies than in the absence of the chemical species. All preferredfeatures for the first ion exchange material, with respect to the firstelectrode, are also preferred for the second ion exchange materialwithrespect to the second electrode. The first and second ion exchangematerials may be comprises of the same or different materials.

In one embodiment, the electrodes are preferably elongate and form partof an electrical circuit which can measure the position, along at leastone of the electrodes, at which the chemical species is present. Forexample, the electrodes may have a length which is substantiallygreater, such as at least 100 times greater, often at least 1,000 timesgreater, sometimes at least 10,000 times greater than either of itsother dimensions. Such an arrangement not only detects the presence ofthe chemical species but also its location.

The invention may be used to detect chemical species in a number ofenvironments. For example, the electrodes may be placed adjacent a pipeor receptacle containing a liquid containing the chemical species. Forexample the electrodes may be wrapped around the pipe or container, orplaced underneath the pipe or container, or where the pipe or containerare buried in the soil, the electrodes may be buried adjacent the pipeor container. If any liquid leaks from the container or pipe and bridgesthe electrodes, it is detected.

The invention may be used to detect whether or at what concentration achemical species is present in a liquid. This can be done simply byappropriately selecting the ion exchange material on the firstelectrode, and immersing the first and second electrodes in the liquid.The invention can also be used as a level sensor. This can be done bysuspending the electrodes above a liquid containing the chemical speciessuch that a rise in the level of the liquid is detected.

A preferred instance of detecting concentratino is the determination ofthe state of charge of a battery or single cell, for example a lead-acidaccumulator. Here the need for charging could be indicated by a sensorcell that indicated that pH had risen above a threshold value, or a moreaccurate state of charge could be indicated by moniting pH over a range.A signal from the sensor cell could then simply activate a warning, orcould be used to control a generator.

Referring now to the drawings FIG. 7 shows an article comprising a flatconductive polymer electrodes 72. A copper mesh 74 and an insulatingjacket 76 are applied to one side of electrode 72 and a layer of ionexchange material 78 is bonded to the opposite surface of the electrode72. Where the article is to be used to detect the prsence of hydrogenoins the ion exchange material may comprise units of the formula P--C₅H₄ N. Where the article is to be used to detect the presence of basicliquids the ion exchange material may comprise units containing acarboxylic acid group or a phenol group. FIG. 8 shows an article whichcomprises a metallic support core 82 surrounded by a layer of conductivepolymer 84 to which is bonded an ion exchange material 86 comprisingunits of the formula P--C₅ H₄ N.

FIG. 9 illustrates an appartus which can be used in the invention todetect the presence of sufficient concentrations of hydrogen ions in abath of liquid. The article of FIG. 8, shown in FIG. 9 as 90, isimmersed in a bath of liquid 91. A counter, or second, electrode 92 isalso immersed inthe bath. A voltage 94 is applied to the electrodes sothat electrode 90 is the cathode and the counter electrode 92 is theanode. An ammeter 96 is arranged to monitor the current. In thesubstantial absence of hydrogen ions the oin exchange material on theelectrode 90 is les ionically conductive. Hence the current monitored onthe ammeter 16 is small (of the order of 10⁻⁸ A/cm² in one embodiment).When the ion exchange material is exposed to hydrogen ions, e.g. whenthe liquid comprises an acid, the material becomes more ionicallyconductive, and a current of the order of 10⁻⁴ A/cm² may be monitored onthe a meter 96.

FIG. 10 is a cross-sectonal view of a device which incorporates thearticle of FIG. 8 and which can be used to detect the presence ofhydrogen oins. The device comprises two electrode wires 100 according tothe FIG. 8 and two return wires 101 comprising a metallic core 102having an insulating jacket 104. A braid or other jacket (not shown) maysurround the wires. A braid may provide mechanical protection and mayalso hold the wires together.

FIG. 11 is a schematic drawing showing a circuit in which articlesaccording to the invention may be incorporated. The circuit comprises asource wire 11, locating wire 112, a return wire 114, a constant currentpower supply, and a voltmeter. Wires 110 and 112 are initially separatedfrom each other but can be connected by an event Ek such as a leak ofelectrolyte. When connection is made, a test circuti is formedcomprising wires 110, 112 and the event E. A constant current I isdriven through that circuti. Locating wire 112 has a known impedancewhich is constant or varies in a known way along its length, andtogether with return wire 114 forms a reference circuit, in which thevoltage measuring device is included. Provided the impedance values ofall the elements in the reference circiut are known, and given thevoltage measurement of the reference circit and the known currentflowing through thelocating wire 112 it is possible to determine theposition of event E. In the circuit illustrated, all of the current Iwill flow through event E, and if a high impedance voltmter is used acurrent substantially equal toI may be assumed to flow along locatingmember 112 between a first point 116 and a second point 118. The voltagedrop measured by the voltmeter will propportional (or some other knownfunction) of the distance between the first and second points. Thepositoins of the power source and voltmeter may be reversed, but thenestimation of the currents in the various paths may be more difficult.

A device as shown in FIG. 10, for exampe, may be included in the circuitof FIG. 11, articles 100 providing the source and locating wires 110 and112, and one of the insulated wires 101 proiding the return wire 114.The event E which causes connectionof the two wires 100 is the increasein the polymeric member's ionic conductivity, resulting from thepresence of the chemical species. For an acid sensor this increasedconductivity is caused by the presence of the hydrogen ions.

An embodiment of the invention is now described with reference to thefollowing example:

EXAMPLE 8

Ion exchange material may alsobe applied to a wire. As an example, asolution was prepared from 51.3 mole percent 4-vinylpyridine, 31.0%2-ethylhexylacrylate, 3.7% technical divinylbenzene, 4.0% benzoylperoxide, and 10% of a linear polymr for thickening. This polymerconsisted of 65 mole percent 4-vinylpyridine and 35% 2- ethylhexylacrylate, was produced in a free radical polymerization in a precedingstep, and had a weight average molecular weight of approximately 200,00.Ten percent of this thickening polymer produced a solutino of 800 cps. A1.10 mm diameter conductive polymer wire (with a 24 gauge metallic core)was dipped in this thickened solution and drawn upward into and througha ten foot (3.3 m) heating tower held at 135° C. The wire with a1.2×10⁻⁴ m coating of ion exchange material was spooled at roomtemperature and sampes could be placed in 1 M HCl to produce thepyridinium chloride form of the ion exchange layer.

EXAMPLE 9

Source and locating wires as in FIG. 8 for an acid sensor were preparedusing a Copel wire (3 ohm per ft., 0.1 ohm per cm) covered with aconductive polymer jacket comprising a linear low density polyethylenecarbon black blend. The ion exchange material bonded to this wire was100 microns thick and comprised a terpolymer of 35 mole percent4-vinylpyridine, 67 mole percent ethylhexyl acrylate, and 3 mole percenttechnical divinylbenzene. These wires were incorporated in a sensor asdescribed in FIg. 10. After submersion of a 4 inch (10 cm) length ofsensor (or 3 cm² area on each electrode) in tap water (pH-6), forseveral days the current was found to be 2×10⁻⁸ A. This sample was thenexposed to a 3 M HCL liquid, and the current measured as a function oftime. The current reached 3×10⁻⁴ A within 2 minutes, and was rinsed andreplaced in tap water to regenerate. After 20 minutes the current wasreduced to 1.5×10⁻⁵ A, and continued to drop over the next hours anddays to 4×10⁻⁷ A. A representative response/regeneration curve is shownin FIG. 12.

EXAMPLE 10

A second specific example is illustrated in FIGS. 13 and 14. Here, someoperation connected with a battery 130 is controlled. The battery may beof any type, and the one illustrated is a lead-acid accumulatorcomprisng six cells 131, three only of which are shown. The battery hastwo terminals 132 connected to electrode plates 133, of which there maybe many, but two are shown. A sensor cell 134 is shown immersed in theelectrolyte 135 of the battery. The sensor cell, which may be of thetype described above, preferably comprises a casing 136, permeable t theelectrolyte 135, containing first and second electrodes 137, 138, atleast one of which is surrounded by an ion exchange resin 139. Ifdesired one of the battery electrodes 133 may function also as one ofthe sensor cell electrodes.

A known voltage is applied to the first and seocnd electrodes 137,138and the resistance or ipedance between them is measured. The resistancewill depend on the resistance of the ion-exchange resin 139, asexplained above. Thus, an indication of the pH (or other concentration)will be provided. The sensor cell 134 may be positioned such that the pHmeasured gives an accurate indication of the overall state of charge ofthe battery.

A sensor cell 134 may be used to regulate charging, discharging orheating of a battery. FIG. 14 shows its use in regulating charging, in acircuit that may be useful in automobiles such as cars or trucks orother means of transport.

Battery 140 has terminals 141, one of which is connected to earth 142,and the other to various electrical devices, represented generally asload 143. A generator 144 is connected between earth 142 and the liveside of the battery. A computer, or othr control system, 145 controlsthe generato 144 in response to a signal from the sensor cell 134. Apoer supply 146 supplies a fixed voltage to the sensor cell electrodes137,138. The fixed voltage, which is preferable from 2-9 volts,especially from 3-7 volts (in the case of a normally 12 volt lead-acidaccumulator) may be topped from the battery 140 itself since thatvoltage wil be available in all bu the lowest state of discharge. Thecomputer 145 measures curent in the sensor cell circuit, for example bymeasuring the voltage drop across a resistor 66. The resistance of thesensor cell 134 will depend on the pH (or other concentration) withinthe battery 140, and is represented by a variable resistance 147. Thevalue of variable resistance 147 will affect the voltage drop acrossresistor 148. Teh signalthat the computer 145 receives from th sensorcell is used to control the output of generator 144. In this way,charging of the battery can be limited or stopped when its pH reaches asufficiently low value. This may be desirable for extending the cyclelife of batteries.

It can be seen that the power supply 146 is isolated from the anode andcathode of the battery 140. In spite of this isolation, some undesirablecurrent loops can form which may affect the current flowing through thesensor cell. In general, the situation can be improved by employing asensor cell powered by a periodic waveform, for example alternatingvoltage and having some means of DC isolation, for example a capacitor.Since any undesirable voltages due to the battery that may be impressedon the sensor cell circuit will be Dc they will have no effect oncurrent flowing in the sensor cell. An alternating voltage may begenerated simply by standard techniques, adn components may be presentto protect th circuit against surge or transients etc., for example onstarting of a car engine.

In this example and in other embodiments the effect of the battery maybe reduced, at least to some extent by making the measurements of thesensor cell when the battery 146 is open circuit. The battery could beswitched, for example automatically, to open circuit periodically for ashort period toallow the sensor cell to be monitored.

In general it may be desirable that the sensor cell be shielded from anycurrent resulting from operation of the battery 146 itself. Onepossibility is to provide one of the electrodes 137,138 as a hollowcylinder, and the other positioned within it. The annular space betweenthe two could contain the ion exchange resin.

Where the sensor cell is used with a battery (as illustrated) ratherthan with a single cell it may in general be positioned in any of thecells, and the electrodes 137,138 of the sensor cell may have anysuitable spatial relationship with respect to the anodes and cathodes ofthe battery. Where the power supply 146 for the sensor cell isindependent of the battery, in general no series problems will arise.However, if the power supply of the sensor cell is connected to thebattery (for example by their having a common earth) more cars may berequired to prevent unwanted current loops resulting in inaccuratesignals from the sensor cell. Also, different resulsts may be obtaineddepending on which of the cells of the battery contains the sensor cell.This is because the potential of the anodes and cathodes of each cellwill be different with respect to the common earth to which the sensorcell is connected.

This is illustrated in FIG. 15a which shows a sensor cell having acommon earth with that of the battery and which show the sensor cellpositioned in the cell of the battery closest to the common earth, asindicated by the n cells to one side of it. That position is preferredsince undesired curent loops are minimized. In FIG. 15a and sensor isdesigned for alternating voltage and a capacitor is provided to preventdirect current. FIG. 15a could be altered such that the sensingelectrode is powered by a direct voltage where the sensor can be acathode or anode. Some undesired current loops mayexist in thesecircuits, but they may however be satisfactory for some purposes. Theuse of an alternating voltage in the sensor cell, as mentioned above,may be used to advantage.

FIG. 15b shows a sensor cell having one electrode in common with anelectrode of one of the cells of the battery under test. The sensor cellmay be positioned in any cell of the battery, as is indicated by thevariable number of battery cells either side of it. Again, analternating voltage could be used for the sensor cell.

We claim:
 1. A method of replacing an ionic species in an ion exchangematerial containing the ionic species, which method comprises passing acurrent through an electrochemical cell which comprises:(1) a firstelectrode; (2) an ioon exchange material A which(a) contains anionicspecies I_(1A), and (b) is secured to and in electrical and physicalcontact with the first electrode and substantially surrounds allsurfaces of the first electrode; (3) a second electrode; and (4) anelectrolyte which electrically connects the first and secondelectrodes;and in which cell an electrochemical reaction takes place atthe interface between the first electrode and the ion species I_(1A) tobe replaced by another ionic species, substantially all the ionicspecies I_(2A) sogenerated passing through the ion exchange material A.2. A method according to claim 1, wherein(i) the electrochemical celladditionally comprises (5) a second ion exchange material B whic (a)contains an ionic species I_(1B) and (b) is secured to and in electricaland physical contact with the second electrode and substantiallysurrounds all surfaces of the second electrode; and(ii) anelectrochemical reaction takes place at the interface between the secondelectrode and the ion exchange material B and generates an ionic speciesI_(2B) which causes the species I_(1B) to be replace by another ionicspecies, substantially all the ionic species I_(2B) so generated passingthrough the ion exchange material B.
 3. A method of replacing anionicspecies in an ion exchange material containing the ionic species, whichmethod comprises passing a current through an electrochemical cell whichcomprises:(i) a first electrode; (ii) an ion exchange material Awhich(a) contains an ionic species I_(1A), and (b) is secured to and inelectrical and physical contact with the first electrode at an interface(iii) an electrically insulating layer electrically insulating theremaining surfaces of the first electrode not in contact with the ionexchange material; (iv) a second electrode; and (v) an electrolyte whichelectrically connects the first and second electrodes;and in which cellan electrochemical reaction takes place at the interface between thefirst electrode and the ion exchange material A and generates an ionicspecies I_(2A) which causes the ionic species I_(1A) to be replaced byanother ionic species, substantially all the ionic species I_(2A) sogenerated passing through the ion exchange material, the electricallyinsulating layer electrically insulating the remainnig surfaces of thefirst electrode from the electrolyte.
 4. A method of replacing ionicspecies M³⁰ and A⁻ in a device comprising cation and anion ion exchangematerial containing the ioninc species M⁺ and A⁻, respectively, whichmethod comprises passing a current through an electrochemical cell whichcomprises:(i) a stack of planar electrodes in which each electrode isarranged substantially parallel to and spaced apart from any adjacentelectrode, comprising:(a) a first outer electrode at one end of thestack, coated onits inward facing surface with an anion exchangematerial containing the ionic species A⁻, (b) a second outer electrodeat the other end of the stack, coated on its inward facing surface witha cation exchange material containing the inic species M⁺ ; and (c) aplurality of bipolar electrodes located between the first and secondelectrodes, each bipolar electrode being coated on its surface facingtowards the first outer electrode with a cation exchange materialcontaining the ionic species M⁺ and further being coated on its surfacefacing towards the second outer electrode with an anion exchangematerial containing the ionic species A⁻ ; (ii) an electrolyte whichelectrically connects the planar electrodes; whereby an electrochemicalreaction generating H⁺ takes place at the interface between each planarconductive polymer electrode and the catioon exchange material coatedthereon and substantially all the H⁺ so generated passes through thecation exchange material and displaces the ionic species M⁺ therefrom,and an electrochemical reaction generating OH⁻ takes place at theinterface between said planar conductive polymer electrode and the anionexchange material coated thereon and substantially all the OH⁻ sogenerated passes through the anion exchange material and displaces theionic species A⁻ therefrom.
 5. A method according to claim 1, 3 or 4wherein the first electrode comprises a conductive polymer, the ionexchange material being secued to the conductive polymer.
 6. A methodaccording to claim 1, 3, or 4, wherein the ion exchange material has anion exchange capacity of at least 0.1 milliequivalent per gram.
 7. Amethod according to claim 1, 3, or 4, wherein the ion exchange materialhas a thickness of at least 1×10⁻⁶ m.
 8. A method according to claim 1,3, or 4, wherein the ion exchange material is formed by in situpolymerization of ion exchange precursors on the electrode.
 9. A methodaccording to claim 3, wherein(i) the electrochemical cell additionallycomprises (vi) a second ion exchange material B which (a) contains anionic species I_(1B) and (b) is secured to and in electrical andphysical contact with the second electrode at an interface and (vii) afurther electrical insulating layer electrically insulating theremaining surfaces of the second electrode not in contact with the ionexchange material B; and (ii) an electrochemical reaction takes place atthe interface between the second electrode and the ion exchange materialB and generates an ionic species I_(2B) which causes the species I_(1B)to be replace by another ionic species, substantially all the ionicspecies I_(2B) so generated passing through the ion exchange material B.